Tissue stapler anvil feature to prevent premature jaw opening

ABSTRACT

A surgical instrument includes a handle assembly having a trigger operable to fire a staple driver to staple tissue. The instrument includes a pointed rod to which an anvil may be coupled. An anvil detection feature is included to determine when the anvil is coupled to the rod. In some versions, the anvil detection feature comprises a translatable rod that inhibits a lockout feature from disengaging. In other versions, an anvil sensing tube is disposed about the pointed rod and interferes with actuation of the trigger in a first position. A recess in the tube permits trigger to actuate when the anvil sensing tube is in the second position. Alternatively, a resilient tab is coupled to the pointed rod and resists actuation of the staple driver. A trigger lockout assembly may include a spring-loaded button that “pops” out when a push rod is actuated, thereby freeing a pivotable lockout feature.

BACKGROUND

In some settings, a surgeon may want to position a surgical instrumentthrough an orifice of the patient and use the instrument to adjust,position, attach, and/or otherwise interact with tissue within thepatient. For instance, in some surgical procedures, portions of thegastrointestinal tract may be cut and removed to eliminate undesirabletissue or for other reasons. Once the desired tissue is removed, theremaining portions will need to be recoupled together. One such tool foraccomplishing these anastomotic procedures is a circular stapler that isinserted through a patient's orifice.

Examples of such circular surgical staplers are described in U.S. Pat.No. 5,205,459, entitled “Surgical Anastomosis Stapling Instrument,”issued Apr. 27, 1993; U.S. Pat. No. 5,271,544, entitled “SurgicalAnastomosis Stapling Instrument,” issued Dec. 21, 1993; U.S. Pat. No.5,275,322, entitled “Surgical Anastomosis Stapling Instrument,” issuedJan. 4, 1994; U.S. Pat. No. 5,285,945, entitled “Surgical AnastomosisStapling Instrument,” issued Feb. 15, 1994; U.S. Pat. No. 5,292,053,entitled “Surgical Anastomosis Stapling Instrument,” issued Mar. 8,1994; U.S. Pat. No. 5,333,773, entitled “Surgical Anastomosis StaplingInstrument,” issued Aug. 2, 1994; U.S. Pat. No. 5,350,104, entitled“Surgical Anastomosis Stapling Instrument,” issued Sep. 27, 1994; andU.S. Pat. No. 5,533,661, entitled “Surgical Anastomosis StaplingInstrument,” issued Jul. 9, 1996. The disclosure of each of theabove-cited U.S. patents is incorporated by reference herein. Some suchstaplers are operable to clamp down on layers of tissue, cut through theclamped layers of tissue, and drive staples through the layers of tissueto substantially seal the severed layers of tissue together near thesevered ends of the tissue layers.

Merely additional other exemplary surgical staplers are disclosed inU.S. Pat. No. 4,805,823, entitled “Pocket Configuration for InternalOrgan Staplers,” issued Feb. 21, 1989; U.S. Pat. No. 5,415,334, entitled“Surgical Stapler and Staple Cartridge,” issued May 16, 1995; U.S. Pat.No. 5,465,895, entitled “Surgical Stapler Instrument,” issued Nov. 14,1995; U.S. Pat. No. 5,597,107, entitled “Surgical Stapler Instrument,”issued Jan. 28, 1997; U.S. Pat. No. 5,632,432, entitled “SurgicalInstrument,” issued May 27, 1997; U.S. Pat. No. 5,673,840, entitled“Surgical Instrument,” issued Oct. 7, 1997; U.S. Pat. No. 5,704,534,entitled “Articulation Assembly for Surgical Instruments,” issued Jan.6, 1998; U.S. Pat. No. 5,814,055, entitled “Surgical ClampingMechanism,” issued Sep. 29, 1998; U.S. Pat. No. 6,978,921, entitled“Surgical Stapling Instrument Incorporating an E-Beam Firing Mechanism,”issued Dec. 27, 2005; U.S. Pat. No. 7,000,818, entitled “SurgicalStapling Instrument Having Separate Distinct Closing and FiringSystems,” issued Feb. 21, 2006; U.S. Pat. No. 7,143,923, entitled“Surgical Stapling Instrument Having a Firing Lockout for an UnclosedAnvil,” issued Dec. 5, 2006; U.S. Pat. No. 7,303,108, entitled “SurgicalStapling Instrument Incorporating a Multi-Stroke Firing Mechanism with aFlexible Rack,” issued Dec. 4, 2007; U.S. Pat. No. 7,367,485, entitled“Surgical Stapling Instrument Incorporating a Multistroke FiringMechanism Having a Rotary Transmission,” issued May 6, 2008; U.S. Pat.No. 7,380,695, entitled “Surgical Stapling Instrument Having a SingleLockout Mechanism for Prevention of Firing,” issued Jun. 3, 2008; U.S.Pat. No. 7,380,696, entitled “Articulating Surgical Stapling InstrumentIncorporating a Two-Piece E-Beam Firing Mechanism,” issued Jun. 3, 2008;U.S. Pat. No. 7,404,508, entitled “Surgical Stapling and CuttingDevice,” issued Jul. 29, 2008; U.S. Pat. No. 7,434,715, entitled“Surgical Stapling Instrument Having Multistroke Firing with OpeningLockout,” issued Oct. 14, 2008; and U.S. Pat. No. 7,721,930, entitled“Disposable Cartridge with Adhesive for Use with a Stapling Device,”issued May 25, 2010. The disclosure of each of the above-cited U.S.patents is incorporated by reference herein. While the surgical staplersreferred to above are described as being used in endoscopic procedures,it should be understood that such surgical staplers may also be used inopen procedures and/or other non-endoscopic procedures.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a side elevation view of an exemplary circular staplingsurgical instrument;

FIG. 2A depicts an enlarged longitudinal cross-section view of anexemplary stapling head assembly of the instrument of FIG. 1 showing anexemplary anvil in an open position;

FIG. 2B depicts an enlarged longitudinal cross-sectional view of thestapling head assembly of FIG. 2A showing the anvil in a closedposition;

FIG. 2C depicts an enlarged longitudinal cross-sectional view of thestapling head assembly of FIG. 2A showing an exemplary staple driver andblade in a fired position;

FIG. 3 depicts an enlarged partial cross-sectional view of an exemplarystaple formed against the anvil;

FIG. 4A depicts an enlarged side elevation view of an exemplary actuatorhandle assembly of the surgical instrument of FIG. 1 with a portion ofthe body removed, showing a trigger in an unfired position and a lockoutfeature in a locked position;

FIG. 4B depicts an enlarged side elevation view of the actuator handleassembly of FIG. 4A, showing the trigger in a fired position and thelockout feature in an unlocked position;

FIG. 5 depicts an enlarged partial perspective view of an exemplaryindicator assembly of the surgical instrument of FIG. 1 showing anindicator window and indicator lever;

FIG. 6 depicts an diagrammatic view of the indicator window of FIG. 5showing an exemplary indicator bar and exemplary corresponding staplerepresentations;

FIG. 7 depicts a partial side cross-sectional view of a surgicalinstrument having an exemplary trocar with an anvil presence rod;

FIG. 8 depicts an enlarged partial cross-sectional view of an exemplaryanvil detection assembly having a resiliently biased tab, an exemplarystaple driver, a trocar, and an anvil;

FIG. 9A depicts a partial cross-sectional view on an alternative anvildetection assembly having a pair of spring clips, shown in an extendedposition;

FIG. 9B depicts a partial cross-sectional view on the anvil detectionassembly of FIG. 9A showing the trocar and spring clips in the retractedposition without an anvil attached;

FIG. 9C depicts a partial cross-sectional view on the anvil detectionassembly shown in the retracted position with the anvil attached;

FIG. 10A depicts an enlarged partial longitudinal cross-sectional viewof an anvil detection assembly having a pair of resiliently biasedlocking features with magnetic portions;

FIG. 10B depicts an enlarged partial longitudinal cross-sectional viewof the anvil detection assembly of FIG. 10A showing a complementaryanvil coupled to the trocar and aligned with the magnetic portions;

FIG. 11 depicts a side cross-sectional view of an exemplary surgicalinstrument having an exemplary anvil detection assembly with an anvilsensing tube;

FIG. 12 depicts an enlarged partial perspective view of the distal endof the anvil detection assembly of FIG. 11;

FIG. 13 depicts an enlarged partial perspective view of anotherexemplary anvil detection assembly having an exemplary alternative anvilpresence tube with a cup;

FIG. 14 depicts an enlarged partial cross-sectional view of yet anotherexemplary anvil detection assembly showing an exemplary alternativeanvil with a split collet shaft and a pair of tabs;

FIG. 15 depicts an enlarged partial cross-sectional view of a furtherexemplary anvil detection assembly showing a trocar with spring-loadedpins;

FIG. 16A depicts a rear cross-sectional view of an exemplary surgicalinstrument showing an exemplary lockout button assembly with a buttonshown in a first position;

FIG. 16B depicts a rear cross-sectional view of the surgical instrumentof FIG. 16A showing the button cammed to a second position;

FIG. 16C depicts a rear cross-sectional view of the surgical instrumentof FIG. 16A showing the button actuated to a third position;

FIG. 17 depicts a side elevation view of the surgical instrument of FIG.16A with a portion of the body removed;

FIG. 18A depicts a rear cross-sectional view of an exemplary surgicalinstrument with an alternative exemplary lockout button assembly, with abutton shown in a first position;

FIG. 18B depicts a rear cross-sectional view of the surgical instrumentof FIG. 18A showing the button cammed to a second position;

FIG. 18C depicts a rear cross-sectional view of the surgical instrumentof FIG. 18A showing the button rotated to a third position;

FIG. 19A depicts a partial perspective view of yet another exemplarylockout button assembly with a button shown in a first position and ananvil pin inserted therethrough;

FIG. 19B depicts a partial perspective view of the lockout buttonassembly of FIG. 19A showing the anvil pin removed;

FIG. 19C depicts a partial perspective view of the lockout buttonassembly of FIG. 19A showing button actuated to a second position;

FIG. 19D depicts a partial perspective view of the lockout buttonassembly of FIG. 19A showing the button rotated to a third position;

FIG. 19E depicts a partial perspective view of the lockout buttonassembly of FIG. 19A showing the button actuated to a fourth position;

FIG. 19F depicts a partial perspective view of the lockout buttonassembly of FIG. 19A showing firing bar actuated relative to the buttonin the fourth position;

FIG. 20A depicts a side cross-sectional view of an exemplary surgicalinstrument having an alternative lockout button assembly shown in afirst position;

FIG. 20B depicts the alternative lockout button assembly of FIG. 20Ashown in a second position;

FIG. 20C depicts the alternative lockout button assembly of FIG. 20Ashowing a proximal end feature pivoting a pivot member;

FIG. 21A depicts a schematic view of an exemplary interlock safetyassembly shown in a locked position;

FIG. 21B depicts a schematic view of the interlock safety assembly ofFIG. 21A shown in an unlocked position;

FIG. 22 depicts an enlarged partial perspective view of the interlocksafety assembly of FIG. 21A showing an exemplary anvil rod in the lockedposition; and

FIG. 23 depicts an enlarged partial perspective view of the interlocksafety assembly of FIG. 21A showing an exemplary safety lever in thelocked position.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

I. Overview of Exemplary Circular Stapling Surgical Instrument

FIGS. 1-6 depict an exemplary circular surgical stapling instrument (10)having a stapling head assembly (20), a shaft assembly (60), and anactuator handle assembly (70), each of which will be described in moredetail below. Shaft assembly (60) extends distally from actuator handleassembly (70) and stapling head assembly (20) is coupled to a distal endof shaft assembly (60). In brief, actuator handle assembly (70) isoperable to actuate a staple driver (24) of stapling head assembly (20)to drive a plurality of staples (66) out of stapling head assembly (20).Staples (66) are bent to form completed staples by an anvil (40) that isattached at the distal end of instrument (10). Accordingly, tissue (2),shown in FIGS. 2A-2C, may be stapled utilizing instrument (10).

In the present example, instrument (10) comprises a closure system and afiring system. The closure system comprises a trocar (38), a trocaractuator (39), and a rotating knob (98). An anvil (40) may be coupled toa distal end of trocar (38). Rotating knob (98) is operable tolongitudinally translate trocar (38) relative to stapling head assembly(20), thereby translating anvil (40) when anvil (40) is coupled totrocar (38), to clamp tissue between anvil (40) and stapling headassembly (20). The firing system comprises a trigger (74), a triggeractuation assembly (84), a driver actuator (64), and a staple driver(24). Staple driver (24) includes a knife (36) configured to severtissue when staple driver (24) is actuated longitudinally. In addition,staples (66) are positioned distal to a plurality of staple drivingmembers (30) of staple driver (24) such that staple driver (24) alsodrives staples (66) distally when staple driver (24) is actuatedlongitudinally. Thus, when trigger (74) is actuated and triggeractuation assembly (84) actuates staple driver (24) via driver actuator(64), knife (36) and members (30) substantially simultaneously severtissue (2) and drive staples (66) distally relative to stapling headassembly (20) into tissue. The components and functionalities of theclosure system and firing system will now be described in greaterdetail.

A. Exemplary Anvil

As shown in FIGS. 1-2C, anvil (40) is selectively coupleable toinstrument (10) to provide a surface against which staples (66) may bebent to staple material contained between stapling head assembly (20)and anvil (40). Anvil (40) of the present example is selectivelycoupleable to a trocar or pointed rod (38) that extends distallyrelative to stapling head assembly (20). Referring to FIGS. 2A-2C, anvil(40) is selectively coupleable via the coupling of a proximal shaft (42)of anvil (40) to a distal tip of trocar (38). Anvil (40) comprises agenerally circular anvil head (48) and a proximal shaft (42) extendingproximally from anvil head (48). In the example shown, proximal shaft(42) comprises a tubular member (44) having resiliently biased retainingclips (46) to selectively couple anvil (40) to trocar (38), though thisis merely optional, and it should be understood that other retentionfeatures for coupling anvil (40) to trocar (38) may be used as well. Forexample, C-clips, clamps, threading, pins, adhesives, etc. may beemployed to couple anvil (40) to trocar (38). In addition, while anvil(40) is described as selectively coupleable to trocar (38), in someversions proximal shaft (42) may include a one-way coupling feature suchthat anvil (40) cannot be removed from trocar (38) once anvil (40) isattached. Merely exemplary one-way features include barbs, one waysnaps, collets, collars, tabs, bands, etc. Of course still otherconfigurations for coupling anvil (40) to trocar (38) will be apparentto one of ordinary skill in the art in view of the teachings herein. Forinstance, trocar (38) may instead be a hollow shaft and proximal shaft(42) may comprise a sharpened rod that is insertable into the hollowshaft.

Anvil head (48) of the present example comprises a plurality of stapleforming pockets (52) formed in a proximal face (50) of anvil head (48).Accordingly, when anvil (40) is in the closed position and staples (66)are driven out of stapling head assembly (20) into staple formingpockets (52), as shown in FIG. 2C, legs (68) of staples (66) are bent toform completed staples. It should be understood that staple formingpockets (52) are merely optional and may be omitted in some versions.

With anvil (40) as a separate component, it should be understood thatanvil (40) may be inserted and secured to a portion of tissue (2) priorto being coupled to stapling head assembly (20). By way of example only,anvil (40) may be inserted into and secured to a first tubular portionof tissue (2) while instrument (10) is inserted into and secured to asecond tubular portion of tissue (2). For instance, the first tubularportion of tissue (2) may be sutured to or about a portion of anvil(40), and the second tubular portion of tissue (2) may be sutured to orabout trocar (38).

As shown in FIG. 2A, anvil (40) is then coupled to trocar (38). Trocar(38) of the present example is shown in a distal most actuated position.Such an extended position for trocar (38) may provide a larger area towhich tissue (2) may be coupled prior to attachment of anvil (40). Inaddition, the extended position of trocar (38) may also provide foreasier attachment of anvil (40) to trocar (38). Trocar (38) furtherincludes a tapered distal tip. Such a tip may be capable of piercingthrough tissue and/or aiding the insertion of anvil (40) on to trocar(38), though the tapered distal tip is merely optional. For instance, inother versions trocar (38) may have a blunt tip. In addition, or in thealternative, trocar (38) may include a magnetic portion (not shown)which may attract anvil (40) towards trocar (38). Of course stillfurther configurations and arrangements for anvil (40) and trocar (38)will be apparent to one of ordinary skill in the art in view of theteachings herein.

When anvil (40) is coupled to trocar (38), the distance between aproximal face of the anvil (40) and a distal face of stapling headassembly (20) defines a gap distance d. Trocar (38) of the presentexample is translatable longitudinally relative to stapling headassembly (20) via an adjusting knob (98) located at a proximal end ofactuator handle assembly (70), as will be described in greater detailbelow. Accordingly, when anvil (40) is coupled to trocar (38), rotationof adjusting knob (98) enlarges or reduces gap distance d by actuatinganvil (40) relative to stapling head assembly (20). For instance, asshown sequentially in FIGS. 2A-2B, anvil (40) is shown actuatingproximally relative to actuator handle assembly (70) from an initial,open position to a closed position, thereby reducing the gap distance dand the distance between the two portions of tissue (2) to be joined.Once the gap distance d is brought within a predetermined range,stapling head assembly (20) may be fired, as shown in FIG. 2C, to stapleand sever tissue (2) between anvil (40) and stapling head assembly (20).Stapling head assembly (20) is operable to staple and sever tissue (2)by a user pivoting a trigger (74) of actuator handle assembly (70), aswill be described in greater detail below.

As noted above, gap distance d corresponds to the distance between anvil(40) and stapling head assembly (20). When instrument (10) is insertedinto a patient, this gap distance d may not be easily viewable.Accordingly, a moveable indicator bar (110), shown in FIGS. 5-6, isprovided to be visible through an indicator window (120) positionedopposite to trigger (74). Indicator bar (110) is operable to move inresponse to rotation of adjusting knob (98) such that the position ofindicator bar (110) is representative of the gap distance d. As shown inFIG. 6, indicator window (120) further comprises a scale (130) whichindicates that the anvil gap is within a desired operating range (e.g.,a green colored region or “green zone”) and a corresponding staplecompression representation at each end of scale (130). By way of exampleonly, as shown in FIG. 6, a first staple image (132) depicts a largestaple height while a second staple image (134) depicts a small stapleheight. Accordingly, a user can view the position of the coupled anvil(40) relative to the stapling head assembly (20) via indicator bar (110)and scale (130). The user may then adjust the positioning of anvil (40)via adjusting knob (98) accordingly.

Referring back to FIGS. 2A-2C, a user sutures a portion of tissue (2)about tubular member (44) such that anvil head (48) is located within aportion of the tissue (2) to be stapled. When tissue (2) is attached toanvil (40), retaining clips (46) and a portion of tubular member (44)protrude out from tissue (2) such that the user may couple anvil (40) totrocar (38). With tissue (2) coupled to trocar (38) and/or anotherportion of stapling head assembly (20), the user attaches anvil (40) totrocar (38) and actuates anvil (40) proximally towards stapling headassembly (20) to reduce the gap distance d. Once instrument (10) iswithin the operating range, the user then staples together the ends oftissue (2), thereby forming a substantially contiguous tubular portionof tissue (2).

Anvil (40) may be further constructed in accordance with at least someof the teachings of U.S. Pat. No. 5,205,459; U.S. Pat. No. 5,271,544;U.S. Pat. No. 5,275,322; U.S. Pat. No. 5,285,945; U.S. Pat. No.5,292,053; U.S. Pat. No. 5,333,773; U.S. Pat. No. 5,350,104; U.S. Pat.No. 5,533,661, the disclosures of which are incorporated by referenceherein; and/or in accordance with other configurations as will beapparent to one of ordinary skill in the art in view of the teachingsherein.

B. Exemplary Stapling Head Assembly

Stapling head assembly (20) of the present example is coupled to adistal end of shaft assembly (60) and comprises a tubular casing (22)housing a slidable staple driver (24) and a plurality of staples (66)contained within staple pockets (32). Staples (66) and staple pockets(32) are disposed in a circular array about tubular casing (22). In thepresent example, staples (66) and staple pockets (32) are disposed in apair of concentric annular rows of staples (66) and staple pockets (32).Staple driver (24) is operable to actuate longitudinally within tubularcasing (22) in response to rotation of trigger (74) of actuator handleassembly (70). As shown in FIGS. 2A-2C, staple driver (24) comprises aflared cylindrical member having a trocar opening (26), a central recess(28), and a plurality of members (30) disposed circumferentially aboutcentral recess (28) and extending distally relative to shaft assembly(60). Each member (30) is configured to contact and engage acorresponding staple (66) of the plurality of staples (66) within staplepockets (32). Accordingly, when staple driver (24) is actuated distallyrelative to actuator handle assembly (70), each member (30) drives acorresponding staple (66) out of its staple pocket (32) through a stapleaperture (34) formed in a distal end of tubular casing (22). Becauseeach member (30) extends from staple driver (24), the plurality ofstaples (66) are driven out of stapling head assembly (20) atsubstantially the same time. When anvil (40) is in the closed position,staples (66) are driven into staple forming pockets (52) to bend legs(68) of the staples (66), thereby stapling the material located betweenanvil (40) and stapling head assembly (20). FIG. 3 depicts one merelyexemplary staple (66) driven by a member (30) into a staple formingpocket (32) of anvil (40) to bend legs (68).

Staple driver (24) further includes a cylindrical knife (36) that iscoaxial to trocar opening (26) and inset from staple pockets (32). Inthe present example, cylindrical knife (36) is disposed within centralrecess (28) to translate distally with staple driver (24). When anvil(40) is secured to trocar (38), as described above, anvil head (48)provides a surface against which cylindrical knife (36) cuts thematerial contained between anvil (40) and stapling head assembly (20).In some versions, anvil head (48) may include a recess (not shown) forcylindrical knife (36) to aid in cutting the material (e.g., byproviding a cooperative shearing edge). In addition, or in thealternative, anvil head (48) may include one or more opposingcylindrical knives (not shown) offset from cylindrical knife (36) suchthat a scissor-type cutting action may be provided. Still otherconfigurations will be apparent to one of ordinary skill in the art inview of the teachings herein. Stapling head assembly (20) is thusoperable to both staple and cut tissue (2) substantially simultaneouslyin response to actuation by actuator handle assembly (70).

Of course stapling head assembly (20) may be further constructed inaccordance with at least some of the teachings of U.S. Pat. No.5,205,459; U.S. Pat. No. 5,271,544; U.S. Pat. No. 5,275,322; U.S. Pat.No. 5,285,945; U.S. Pat. No. 5,292,053; U.S. Pat. No. 5,333,773; U.S.Pat. No. 5,350,104; U.S. Pat. No. 5,533,661, the disclosures of whichare incorporated by reference herein; and/or in accordance with otherconfigurations as will be apparent to one of ordinary skill in the artin view of the teachings herein.

As noted previously, staple driver (24) includes a trocar opening (26).Trocar opening (26) is configured to permit trocar (38) tolongitudinally slide relative to stapling head assembly (20) and/orshaft assembly (60). As shown in FIGS. 2A-2C, trocar (38) is coupled toa trocar actuator (39) such that trocar (38) can be actuatedlongitudinally via rotation of rotating knob (98), as will be describedin greater detail below in reference to actuator handle assembly (70).In the present example, trocar actuator (39) comprises an elongated,relatively stiff shaft coupled to trocar (38), though this is merelyoptional. In some versions, actuator (39) may comprise a longitudinallystiff material while permitting lateral bending such that portions ofinstrument (10) may be selectively bent or curved during use; orinstrument (10) may include a preset bent shaft assembly (60). Onemerely exemplary material is nitinol. When anvil (40) is coupled totrocar (38), trocar (38) and anvil (40) are translatable via actuator(39) to adjust the gap distance d between anvil (40) and stapling headassembly (20). Still further configurations for actuator (39) tolongitudinally actuate trocar (38) will be apparent to one of ordinaryskill in the art in view of the teachings herein.

C. Exemplary Shaft Assembly

Stapling head assembly (20) and trocar (38) are positioned at a distalend of shaft assembly (60), as shown in FIGS. 2A-2C. Shaft assembly (60)of the present example comprises an outer tubular member (62) and adriver actuator (64). Outer tubular member (62) is coupled to tubularcasing (22) of stapling head assembly (20) and to a body (72) ofactuator handle assembly (70), thereby providing a mechanical ground forthe actuating components therein. The proximal end of driver actuator(64) is coupled to a trigger actuation assembly (84) of actuator handleassembly (70), described below. The distal end of driver actuator (64)is coupled to staple driver (24) such that the rotation of trigger (74)longitudinally actuates staple driver (24). As shown in FIGS. 2A-2C,driver actuator (64) comprises a tubular member having an openlongitudinal axis such that actuator (39) coupled to trocar (38) mayactuate longitudinally within and relative to driver actuator (64). Ofcourse it should be understood that other components may be disposedwithin driver actuator (64) as will be apparent to one of ordinary skillin the art in view of the teachings herein.

Shaft assembly (60) may be further constructed in accordance with atleast some of the teachings of U.S. Pat. No. 5,205,459; U.S. Pat. No.5,271,544; U.S. Pat. No. 5,275,322; U.S. Pat. No. 5,285,945; U.S. Pat.No. 5,292,053; U.S. Pat. No. 5,333,773; U.S. Pat. No. 5,350,104; U.S.Pat. No. 5,533,661, the disclosures of which are incorporated byreference herein; and/or in accordance with other configurations as willbe apparent to one of ordinary skill in the art in view of the teachingsherein.

D. Exemplary Actuator Handle Assembly

Referring now to FIGS. 4A-5, actuator handle assembly (70) comprises abody (72), a trigger (74), a lockout feature (82), a trigger actuationassembly (84), and a trocar actuation assembly (90). Trigger (74) of thepresent example is pivotably mounted to body (72) and is coupled totrigger actuation assembly (84) such that rotation of trigger (74) froman unfired position (shown in FIG. 4A) to a fired position (shown inFIG. 4B) actuates driver actuator (64) described above. A spring (78) iscoupled to body (72) and trigger (74) to bias trigger (74) towards theunfired position. Lockout feature (82) is a pivotable member that iscoupled to body (72). In a first, locked position, lockout feature (82)is pivoted upwards and away from body (72) such that lockout feature(82) engages trigger (74) and mechanically resists actuation of trigger(74) by a user. In a second, unlocked position, such as that shown inFIGS. 1 and 4B, lockout feature (82) is pivoted downward such thattrigger (74) may be actuated by the user. Accordingly, with lockoutfeature (82) in the second position, trigger (74) can engage a triggeractuation assembly (84) to fire instrument (10).

As shown in FIGS. 4A-4B, trigger actuation assembly (84) of the presentexample comprises a slidable trigger carriage (86) engaged with aproximal end of driver actuator (64). Carriage (86) includes a set oftabs (88) on a proximal end of carriage (86) to retain and engage a pairof trigger arms (76) extending from trigger (74). Accordingly, whentrigger (74) is pivoted, carriage (86) is actuated longitudinally andtransfers the longitudinal motion to driver actuator (64). In theexample shown, carriage (86) is fixedly coupled to the proximal end ofdriver actuator (64), though this is merely optional. Indeed, in onemerely exemplary alternative, carriage (86) may simply abut driveractuator (64) while a distal spring (not shown) biases driver actuator(64) proximally relative to actuator handle assembly (70).

Trigger actuation assembly (84) may be further constructed in accordancewith at least some of the teachings of U.S. Pat. No. 5,205,459; U.S.Pat. No. 5,271,544; U.S. Pat. No. 5,275,322; U.S. Pat. No. 5,285,945;U.S. Pat. No. 5,292,053; U.S. Pat. No. 5,333,773; U.S. Pat. No.5,350,104; U.S. Pat. No. 5,533,661, the disclosures of which areincorporated by reference herein; and/or in accordance with otherconfigurations as will be apparent to one of ordinary skill in the artin view of the teachings herein.

Body (72) also houses a trocar actuation assembly (90) configured toactuate trocar (38) longitudinally in response to rotation of adjustingknob (98). As best shown in FIGS. 4A-5, trocar actuation assembly (90)of the present example comprises adjusting knob (98), a grooved shank(94), and a sleeve (92). Grooved shank (94) of the present example islocated at a distal end of trocar actuator (39), though it should beunderstood that grooved shank (94) and trocar actuator (39) mayalternatively be separate components that engage to transmitlongitudinal movement. Adjusting knob (98) is rotatably supported by theproximal end of body (72) and is operable to rotate sleeve (92) that isengaged with grooved shank (94) via an internal tab (not shown). Groovedshank (94) of the present example comprises a continuous groove (96)formed in the outer surface of grooved shank (94). Accordingly, whenadjusting knob (98) is rotated, the internal tab rides within groove(96) and grooved shank (94) is longitudinally actuated relative tosleeve (92). Since grooved shank (94) is located at the distal end oftrocar actuator (39), rotating adjusting knob (98) in a first directionadvances trocar actuator (39) distally relative to actuator handleassembly (70). Accordingly, the gap distance d between anvil (40) andstapling head assembly (20) is increased. By rotating adjusting knob(98) in the opposite direction, trocar actuator (39) is actuatedproximally relative to actuator handle assembly (70) to reduce the gapdistance d between anvil (40) and stapling head assembly (20). Thus,trocar actuation assembly (90) is operable to actuate trocar (38) inresponse to rotating adjustment knob (98). Of course otherconfigurations for trocar actuation assembly (90) will be apparent toone of ordinary skill in the art in view of the teachings herein.

Groove (96) of the present example comprises a plurality of differentportions (96A, 96B, 96C) that have a varying pitch or number of groovesper axial distance. The present groove (96) is divided into a distalportion (96A), a middle portion (96B) and a proximal portion (96C). Asshown in FIG. 5, distal portion (96A) comprises a fine pitch or a highnumber of grooves over a short axial distance of grooved shank (94) suchthat a large number of rotations of adjusting knob (98) are required totraverse the short axial distance. Middle portion (96B) comprises asection with comparably coarser pitch or fewer grooves per axialdistance such that relatively few rotations are required to traverse along axial distance. Accordingly, the gap distance d may be quicklyreduced through relatively few rotations of adjusting knob (98).Proximal portion (96C) of the present example is substantially similarto distal portion (96A) and comprises a fine pitch or a high number ofgrooves over a short axial distance of grooved shank (94) such that alarge number of rotations are required to traverse the short axialdistance. Proximal portion (96C) of the present example is positionedwithin sleeve (92) when anvil (40) is substantially near to staplinghead assembly (20) such that indicator bar (110) moves within indicatorwindow (120) along scale (130) to indicate that the anvil gap is withina desired operating range, as will be described in more detail below.Accordingly, when the tab is within proximal portion (96C) of groove(96), each rotation of adjusting knob (98) may reduce the gap distance dby a small amount to provide for fine tuning.

Trocar actuation assembly (90) may be further constructed in accordancewith at least some of the teachings of U.S. Pat. No. 5,205,459; U.S.Pat. No. 5,271,544; U.S. Pat. No. 5,275,322; U.S. Pat. No. 5,285,945;U.S. Pat. No. 5,292,053; U.S. Pat. No. 5,333,773; U.S. Pat. No.5,350,104; U.S. Pat. No. 5,533,661, the disclosures of which areincorporated by reference herein; and/or in accordance with otherconfigurations as will be apparent to one of ordinary skill in the artin view of the teachings herein.

In the example shown in FIGS. 4A-4B, a U-shaped clip (100) is attachedto an intermediate portion of trocar actuator (39) located distally ofgrooved shank (94). U-shaped clip (100) engages with a portion of body(72) to substantially prevent trocar actuator (39) from rotating aboutits axis when adjusting knob (98) is rotated. U-shaped clip (100)further includes an elongated slot (102) on each of its opposite sidesfor receiving an attachment member, such as a screw, bolt, pin, clip,etc., to selectively adjust the longitudinal position of elongated slot(102) of U-shaped clip (100) relative to trocar actuator (39) forpurposes of calibrating indicator bar (110) relative to scale (130).

As shown in FIG. 5, actuator handle assembly (70) further includes anindicator bracket (140) configured to engage and pivot an indicator(104). Indicator bracket (140) of the present example is slidablerelative to body (72) along a pair of slots formed on body (72).Indicator bracket (140) comprises a rectangular plate (144), anindicator arm (146), and an angled flange (142). Angled flange (142) isformed at the proximal end of rectangular plate (144) and includes anaperture (not shown) to slidable mount onto trocar actuator (39) and/orgrooved shank (94). A coil spring (150) is interposed between flange(142) and a boss (152) to bias flange (142) against U-shaped clip (100).Accordingly, when U-shaped clip (100) actuates distally with trocaractuator (39) and/or grooved shank (94), coil spring (150) urgesindicator bracket (140) to travel distally with U-shaped clip (100). Inaddition, U-shaped clip (100) urges indicator bracket (140) proximallyrelative to boss (152) when trocar actuator (39) and/or grooved shank(94) translate proximally, thereby compressing coil spring (150). Ofcourse, it should be understood that in some versions indicator bracket(140) may be fixedly attached to trocar actuator (39) and/or groovedshank (94).

In the present example, a portion of lockout feature (82) abuts asurface (141) of indicator bracket (140) when indicator bracket (140) isin a longitudinal position that does not correspond to when the anvilgap is within a desired operating range (e.g., a green colored region or“green zone”). When the anvil gap is within a desired operating range(e.g., a green colored region or “green zone”), indicator bracket (140)narrows to provide a pair of gaps (145) on either side of an indicatorarm (146) that permits lockout feature (82) to pivot, thereby releasingtrigger (74). Accordingly, lockout feature (82) and indicator bracket(140) can substantially prevent a user from releasing and operatingtrigger (74) until anvil (40) is in a predetermined operating range. Ofcourse it should be understood that lockout feature (82) may be omittedentirely in some versions.

This operating range may be visually communicated to the user via anindicator bar (110) of an indicator (104) shown against a scale (130),described briefly above. At the distal end of indicator bracket (140) isa distally projecting indicator arm (146) which terminates at alaterally projecting finger (148) for controlling the movement ofindicator (104). Indicator arm (146) and finger (148), best shown inFIG. 5, are configured to engage a tab (106) of indicator (104) suchthat indicator (104) is pivoted when indicator bracket (140) is actuatedlongitudinally. In the present example, indicator (104) is pivotablycoupled to body (72) at a first end of indicator (104), though this ismerely optional and other pivot points for indicator (104) will beapparent to one of ordinary skill in the art in view of the teachingsherein. An indicator bar (110) is positioned on the second end ofindicator (104) such that indicator bar (110) moves in response to theactuation of indicator bracket (140). Accordingly, as discussed above,indicator bar (110) is displayed through an indicator window (120)against a scale (130) (shown in FIG. 6) to show the relative gapdistance d between anvil (40) and stapling head assembly (20).

Of course indicator bracket (140), indicator (104), and/or actuatorhandle assembly (70) may be further constructed in accordance with atleast some of the teachings of U.S. Pat. No. 5,205,459; U.S. Pat. No.5,271,544; U.S. Pat. No. 5,275,322; U.S. Pat. No. 5,285,945; U.S. Pat.No. 5,292,053; U.S. Pat. No. 5,333,773; U.S. Pat. No. 5,350,104; U.S.Pat. No. 5,533,661, the disclosures of which are incorporated byreference herein; and/or in accordance with other configurations as willbe apparent to one of ordinary skill in the art in view of the teachingsherein.

II. Exemplary Anvil Detection, Indicators, and Lock-Out Features

In some instances, it may be desirable for a user to detect when anvil(40) is sufficiently coupled to trocar (38). Such detection can confirmthat anvil (40) is properly coupled to trocar (38) such that anvil (40)does not move distally relative to staple driver (24) when instrument(10) is fired. The indicator for such detection may be provided througha sensory indicator assembly (e.g., visual, auditory, tactile, etc.)and/or through a trigger lock-out assembly to prevent trigger (74) frombeing actuatable by the user. Accordingly, a user may be able todetermine whether anvil (40) is properly attached, or fully seated ontrocar (38), prior to firing instrument (10) or, in some instances,instrument (10) will prevent the user from firing until anvil (40) isproperly attached. Accordingly, various anvil detection assemblies,indicator assemblies, and trigger lockout assemblies will now bedescribed below.

A. Exemplary Anvil Presence Rod

FIG. 7 depicts a surgical instrument (200) that includes an exemplaryanvil presence rod (230) incorporated into an exemplary trocar (220). Inthe present example, surgical instrument (200) comprises a body (202), atrigger (204), a lockout feature (210), an adjusting knob (216), atrocar (220), and an anvil presence rod (230). Body (202), trigger(204), lockout feature (210), adjusting knob (216), and trocar (220),may be constructed in substantial accordance with body (72), trigger(74), lockout feature (82), adjusting knob (98) and trocar (38)described above. Surgical instrument (200) may be further constructedsubstantially in accordance with surgical instrument (10) describedabove, or in accordance with at least some of the teachings of U.S. Pat.No. 5,205,459; U.S. Pat. No. 5,271,544; U.S. Pat. No. 5,275,322; U.S.Pat. No. 5,285,945; U.S. Pat. No. 5,292,053; U.S. Pat. No. 5,333,773;U.S. Pat. No. 5,350,104; and/or U.S. Pat. No. 5,533,661, the disclosuresof which are incorporated by reference herein.

In the present example, trocar (220) includes a central rod tube (222)configured to slidably receive anvil presence rod (230) therein. Anvilpresence rod (230) comprises a longitudinally stiff rod member that isslidable within rod tube (222) of trocar (220) and extends into anaperture (218) formed through adjusting knob (216). As shown in FIG. 7,anvil presence rod (230) is positioned in an unactuated position. Anvilpresence rod (230) is slid proximally relative to trocar (220) when ananvil, such as anvil (40) shown in FIGS. 1-6, is inserted onto trocar(220), thereby moving anvil presence rod (230) proximally to an actuatedposition. This proximal movement of anvil presence rod (230) can be usedto mechanically interact or release components of instrument (200) toindicate when the anvil is properly seated on trocar (220).

In the present example, anvil presence rod (230) includes a proximal end(232) that extends out through an aperture (218) formed in adjustingknob (216) when anvil presence rod (230) is slid proximally relative totrocar (220). This proximal end (232) may include one or more regionsand/or markings (234) to visually indicate the position of anvilpresence rod (230). By way of example only, such markings (234) mayinclude a plurality of colors (e.g., red, yellow, green) and/or symbols(e.g., numbers, letters, etc.) to indicate the longitudinal position ofanvil presence rod (230). In the example shown, markings (234) comprisethree regions (234A, 234B, 234C) corresponding to the colors red (234A),yellow (234B), and green (234C). The user may use markings (234) todetect whether anvil presence rod (230) has been sufficiently actuatedto indicate that the anvil is properly seated on trocar (220). Forinstance, the green marking portion (234C) may correspond to when theanvil has sufficiently coupled to trocar (220) such that the anvil willnot detach when firing instrument (200). The yellow marking portion(234B) of the present example may be provided to indicate to the userthat anvil presence rod (230) has been actuated proximally relative totrocar (220), but the anvil has not fully seated on trocar (220). In onealternative, only a single marking, such as green portion (234C), may beprovided to indicate the position corresponding to when the anvil hassufficiently coupled to trocar (220). Of course it should be understoodthat markings (234) and/or the extension of proximal end (232) out ofaperture (218) of adjusting knob (216) are merely optional.

In addition, anvil presence rod (230) of the present example is biaseddistally by a coil spring (240) that is disposed within a portion oftrocar (220). Accordingly, when no object is actuating anvil presencerod (230) proximally relative to trocar (220), coil spring (240) urgesthe distal end of anvil presence rod (230) out of the distal end of rodtube (222). If a user attempts to couple the anvil to trocar (220) andthe anvil is not properly seated on trocar (220), the distal biasprovided by coil spring (240) ejects the anvil away from trocar (220).Thus, anvil presence rod (230) may physically and visually provide anindication to the user that the anvil is not properly seated on trocar(220). To provide the distal bias to anvil presence rod (230), coilspring (240) is coupled to a portion of anvil presence rod (230) such asby abutting a tab, being fixedly coupled at one end, and/or otherwise.In some versions, proximal end (232) of anvil presence rod (230) may notextend through aperture (218) of adjusting knob (216), but instead abutscoil spring (240) to provide the distal bias. A distal tab or flaredportion (236), shown in FIG. 7, prevents anvil presence rod (230) fromejecting distally out of trocar (220) from the distal bias provided bycoil spring (240), though this is also merely optional.

While a visual indicator may be provided by proximal end (232) and/ormarkings (234), in some versions, a feature may be desired thatsubstantially prevents trigger (204) from being actuated by the useruntil the anvil is properly seated on trocar (220). In the presentexample, lockout feature (210) comprises a pivotable member having a leg(212) that abuts a protrusion (238) of anvil presence rod (230) whenanvil presence rod (230) is in the unactuated position shown in FIG. 7.Protrusion (238) extends outwardly through a slot (224) formed in trocar(220) such that protrusion (238) is longitudinally slidable along slot(224) when anvil presence rod (230) is actuated proximally relative totrocar (220). The longitudinal length of protrusion (238) of the presentexample corresponds to the longitudinal distance traveled by anvilpresence rod (230) to indicate that the anvil is properly coupled totrocar (220). Accordingly, when the anvil is properly coupled,protrusion (238) no longer abuts leg (212) of lockout feature (210). Theuser then pivots lockout feature (210) to unlock and permit operation oftrigger (204) to fire instrument (200). The combination of protrusion(238) and lockout feature (210) may substantially prevent the user fromfiring instrument (10) when the anvil is not properly coupled to trocar(220). In some versions, leg (212) may be integrally formed with orotherwise linked to trigger (204). In some such versions, lockoutfeature (210) may be omitted. Of course other assemblies to preventlockout feature (210) from pivoting prior to actuation of anvil presencerod (230) to the actuated position will be apparent to one of ordinaryskill in the art in view of the teachings herein.

B. Exemplary Resiliently Biased Anvil Detection Features

FIG. 8 depicts an alternative anvil detection assembly (300) that may beincorporated into a surgical instrument, such as surgical instruments(10, 200) described above. In the example shown, anvil detectionassembly (300) comprises a hinged tab (310) extending outwardly from atrocar (302). Trocar (302) may be constructed in accordance with atleast some of the teachings of trocars (38, 220) described above. Asshown in the present example, a spring (312) biases tab (310) outwardlyfrom trocar (302), though this is merely optional. For instance, in onealternative, spring (312) may be omitted and tab (310) may be integrallyformed with trocar (302) such that tab (310) is a resiliently biasedtab. In addition, while a single tab (310) is illustrated, it should beunderstood that a plurality of tabs (310) may be positioned about trocar(302). When tab (310) is extended away from trocar (302), tab (310) ofthe present example mechanically interferes with a staple driver (308)to substantially prevent staple driver (308) from actuating distallyrelative to trocar (302). Accordingly, a user may be prevented fromfiring staple driver (308) via operation of a trigger, such as trigger(74) described above, until tab (310) is depressed against or intotrocar (302).

In the example shown, an anvil (340) comprises an anvil head (342) and ahollow shaft (344). Anvil (340) may be further constructed in accordancewith at least some of the teachings of anvil (40) described above.Hollow shaft (344) comprises a cylindrical tube configured to slide overtrocar (302) and selectively couple anvil (340) to trocar (302). In theexample shown, hollow shaft (344) includes detents (346) that engageindentations (304) of trocar (302) to selectively secure anvil (340) totrocar (302). Of course other coupling assemblies for selectivelycoupling anvil (340) to trocar (302) will be apparent to one of ordinaryskill in the art in view of the teachings herein. When hollow shaft(344) is slid over trocar (302), hollow shaft (344) compresses tab (310)against trocar (302), thereby permitting staple driver (308) to actuatedistally relative to trocar (302) and/or anvil (340) when the useroperates the instrument. In the example shown, the length of hollowshaft (344) is such that hollow shaft (344) only engages tab (310) whenanvil (340) is fully seated on trocar (302). The present assembly maythus prevent a user from firing the device unless anvil (340) isproperly coupled to trocar (302). Of course still further configurationsfor anvil (340), tab (310), and/or trocar (302) will be apparent to oneof ordinary skill in the art in view of the teachings herein.

In addition, or in the alternative, tab (310) may be mechanicallyassociated with a lockout feature in the actuator handle assembly. Byway of example only, tab (310) may comprise a camming surface that isoperable to actuate a rod, such as anvil presence rod (230) describedabove, when tab (310) is compressed against trocar (302). The rod ofthis example may include a protrusion, such as protrusion (238), thatselectively interferes with the release of a lockout feature dependingupon the longitudinal position of the rod. In addition, or in thealternative, the rod may include a proximal end, such as proximal end(232), that protrudes out of the proximal end of the surgical instrumentto provide visual feedback to the user. Of course tab (310) may bemechanically associated with other lockout features and/or visualindicators as will be apparent to one of ordinary skill in the art inview of the teachings herein. In another alternative, tab (310) may bepositioned such that trocar (302) cannot be actuated proximally relativeto staple driver (308) from an extended position via the adjusting knob.For instance, tab (310) may be positioned to abut staple driver (308)while trocar (302) is in the extended position. Accordingly, if the userattempts to actuate trocar (302) proximally via the adjusting knob, tab(310) resists the proximal actuation and provides tactile feedback thattab (310) has not been depressed by attachment of shaft (344) of anvil(340). If trocar (302) is not actuatable proximally due to theinterference of tab (310), then, in an instrument such as instrument(10), a user may not pivot lockout feature (82) to release trigger (74)due to the position of indicator bracket (140), as discussed above.Thus, when tab (310) is extended, a user may be substantially preventedfrom firing the instrument. Of course still further configurations andassemblies incorporating tab (310) will be apparent to one of ordinaryskill in the art in view of the teachings herein.

FIGS. 9A-9C depict an alternative anvil detection assembly (400)comprising a trocar (410) having a pair of spring clips (420). In theexample shown, spring clips (420) are contained within a slot (412)formed in trocar (410). As shown in FIG. 9A, spring clips (420) arebiased outwardly from trocar (410) such that proximal ends (422) extendlaterally from trocar (410). By way of example only, spring clips (420)are coupled to trocar (410) at a pivot point (424) and a spring (notshown) is interposed between spring clips (420) to bias each away fromthe other. In addition, or in the alternative, spring clips (420) maycomprise resiliently biased members that are biased away from pivotpoint (424). In the example shown in FIG. 9A, when spring clips (420)are extended laterally, trocar (410) is prevent from actuatingproximally due to proximal ends (422) engaging a trocar opening (416).Accordingly, if an anvil (440) (shown in FIG. 9C) is not coupled totrocar (410), then trocar (410) is prevented from actuating proximallyrelative to a staple driver (430). If a user desires to actuate trocar(410) proximally relative to staple driver (430) without anvil (440)attached, the user must squeeze spring clips (420) together to permitretraction.

As shown in FIG. 9B, when an anvil (440) (shown in FIG. 9C) is notcoupled to trocar (410) and trocar (410) is retracted proximallyrelative to staple driver (430), spring clips (420) engage notches (432)formed in staple driver (430). As will be apparent to one of ordinaryskill in the art in view of the teachings herein, spring clips (420)inserted into notches (432) substantially prevent staple driver (430)from actuating distally relative to trocar (410). Accordingly, if anvil(440) is not coupled to trocar (410), then spring clips (420) provide alockout mechanism to prevent the instrument from firing. Finally, asshown in FIG. 9C, when anvil (440) is coupled to trocar (410), an anvilshaft (442) cams spring clips (420) inwardly such that proximal ends(422) do not engage notches (432). Accordingly, staple driver (430) canbe actuated distally relative to trocar (410) to fire the instrument.Still further configurations for anvil detection assembly (400) and/orspring clips (420) will be apparent to one of ordinary skill in the artin view of the teachings herein.

C. Exemplary Magnetic Anvil Detection Assembly

FIGS. 10A-10B depict an alternative anvil detection assembly (500) thatmay be incorporated into a surgical instrument, such as surgicalinstrument (10) described above. Referring initially to FIG. 10A, atrocar (510) and a staple driver (520) extend distally from an actuatorhandle assembly (not shown). Trocar (510) and staple driver (520) may beconstructed in accordance with at least some of the teachings of trocar(38) and staple driver (24) described herein. A pair of resilientmembers (530) also extend distally from the actuator handle assembly andare biased outwardly away from trocar (510). The proximal ends (notshown) of resilient members (530) are coupled to a portion of theactuator handle assembly to mechanically ground resilient members (530).For instance, resilient members (530) may be integrally formed with thebody of actuator handle assembly or mechanically coupled via anattachment member, such as a screw, bolt, adhesive, etc. In someversions, the proximal ends of resilient members (530) may be coupled totrocar (510). In another version, the proximal ends of resilient members(530) may be coupled to staple driver (520). Of course still furtherconfigurations to couple resilient members (530) at their proximal endswill be apparent to one of ordinary skill in the art in view of theteachings herein.

Resilient members (530) each comprise an elongated member having alockout arm (532) and a magnet (534). Magnet (534) may be a ferrousmagnet, a neodymium magnet, a samarium-cobalt magnet, or any othersuitable magnet (534) as will be apparent to one of ordinary skill inthe art in view of the teachings herein. Each lockout arm (532) extendsoutward from the longitudinal axis of a corresponding resilient member(530). In the example shown, each lockout arm (532) is perpendicular tothe longitudinal axis of the corresponding resilient member (530) suchthat each lockout arm (532) is configured to mechanically interfere withthe distal actuation of staple driver (520) relative to resilient member(530) and/or trocar (510). Accordingly, when resilient arms (530) are ina locked position, such as that shown in FIG. 10A, staple driver (520)is substantially prevented from actuating distally by lockout arms(532). While only a pair of resilient members (530) are shown, it shouldbe understood that any number of resilient members (530) may be used torestrict distal actuation of staple driver (520). For example, 1, 2, 3,4, 5, or 6 resilient members (530) may be disposed about trocar (510)and configured to interfere with the distal actuation of staple driver(520).

FIG. 10B depicts a complementary anvil (540) for anvil detectionassembly (500). Anvil (540) comprises an anvil head (542) and a shaft(544). Anvil (540) may be further constructed in accordance with atleast some of the teachings of anvil (40) described herein. Shaft (544)of the present example is configured to selectively couple anvil (540)to trocar (510). By way of example only, shaft (544) may comprisedetents (546) configured to engage with indentations (512) (shown inFIG. 10A) of trocar (510) to selectively couple anvil (540) to trocar(510). Shaft (544) further comprises a magnetic portion (548) positionedalong the longitudinal length of shaft (544). Magnetic portion (548) maycomprise a single annular magnet embedded in shaft (544) or a pluralityof magnets disposed within shaft (544). In addition, or in thealternative, magnetic portion (548) may not be embedded within shaft(544) but may be coupled to the exterior or interior surface of shaft(544). Furthermore, magnetic portion (548) may comprise one or moreferrous magnets, neodymium magnets, samarium-cobalt magnets, and/or anyother suitable magnet as will be apparent to one of ordinary skill inthe art in view of the teachings herein. In the present example,magnetic portion (548) is longitudinally positioned to align withmagnets (534) of resilient arms (530) only when anvil (540) is fullyseated on trocar (510).

As shown in FIG. 10B, when anvil (540) is fully seated, magnetic portion(548) attracts magnets (534) such that resilient arms (530) bendinwardly towards shaft (544) and/or trocar (510). Accordingly, lockoutarms (532) no longer mechanically interfere with staple driver (520),thereby permitting staple driver (520) to actuate longitudinally toallow the user to fire the instrument. In one merely exemplaryalternative, resilient arms (530) may omit magnets (534) and may insteadbe constructed of a ferrous material such that magnetic portion (548)attracts resilient arms (530) inwardly. In this configuration, thespring constant for resilient arms (530) may be set such that lockoutarms (532) no longer impede distal movement of staple driver (520) onlywhen anvil (540) is fully seated on trocar (510). By way of exampleonly, as anvil (540) is attached to trocar (510), resilient arms (530)begin to bend inwardly due to magnetic portion (548) magneticallyattracting the material. Only when anvil (540) is seated fully on trocar(510) does the attractive force from magnetic portion (548) on resilientarms (530) displace resilient arms (530) such that lockout arms (532) nolonger impede the longitudinal actuation of staple driver (520). In someversions, resilient arms (530) may comprise magnets (534) while magneticportion (548) of shaft (544) is omitted. Of course still furtherconfigurations for anvil detection assembly (500) will be apparent toone of ordinary skill in the art in view of the teachings herein.

D. Exemplary Outer Shaft Anvil Detection Feature

FIGS. 11-12 depicts yet another anvil detection assembly (620) for asurgical instrument (600) comprising an anvil sensing tube (622)slidably disposed about a trocar (602). As shown in FIG. 11, anvilsensing tube (620) extends proximally into an actuator handle assembly(610). Actuator handle assembly (610) of the present example includes atrigger (614) pivotable relative to a body (612). Trigger (614) includesan arm or feature (616) extending outwardly from a pivot point oftrigger (614) such that arm (616) is pivoted with trigger (614). In someversions, a pair of arms (616) may be provided, such as trigger arms(76) described above. Alternatively, or in addition, arm (616) may be aseparate feature that distinct from trigger arms (76). Instrument (600),trocar (602), and/or actuator handle assembly (610) may be furtherconstructed in accordance with at least some of the teachings forinstrument (10), trocar (38), and/or actuator handle assembly (70)described above.

Anvil sensing tube (622) of the present example comprises a tubularmember coaxially disposed about trocar (602), though it should beunderstood that this is merely optional. In some versions, anvil sensingtube (622) may comprise a longitudinal bar extending along a side oftrocar (602) or anvil sensing tube (622) may include a U-shaped memberpartially encircling a portion of trocar (602). Still furtherconfigurations for anvil sensing tube (622) will be apparent to one ofordinary skill in the art in view of the teachings herein. Anvil sensingtube (622) shown in FIG. 11 includes a notch (624) formed in a proximalportion of anvil sensing tube (622). Accordingly, when anvil sensingtube (622) is in an unactuated position, such as that shown in FIG. 11,notch (624) is not aligned with arm (616). Instead, arm (616) abuts aportion of anvil sensing tube (622) such that trigger (614) cannot bepivoted relative to body (612). When anvil sensing tube (622) isactuated proximally relative to trocar (602) to an actuated position, aswill be discussed in greater detail below, notch (624) is aligned witharm (616) such that trigger (614) is pivotable relative to body (612). Aspring (628) is coupled to a proximal end of anvil sensing tube (622) tobias anvil sensing tube (622) distally relative to actuator handleassembly (610).

In the present example, the longitudinal position of notch (624) islocated such that arm (616) aligns with notch (624) only when an anvil(630) is fully seated on trocar (602) and trocar (602) is actuatedproximally into the “green zone” described above. The “green zone”indicates that the anvil gap, or the distance between the anvil head(not shown) and staple driver (604), is within a desired operatingrange. If anvil (630) is not fully seated on trocar (602), then spring(628) ejects anvil (630) off of trocar (602), as will be discussed inmore detail below. If anvil (630) is fully seated on trocar (602) andnotch (624) and arm (616) are aligned, the user can operate trigger(614) to fire instrument (600). Of course notch (624) may have otherlongitudinal positions on anvil sensing tube (622). Still furtherconfigurations for anvil sensing tube (622) and/or actuator handleassembly (610) will be apparent to one of ordinary skill in the art inview of the teachings herein.

Referring now to FIG. 12, anvil sensing tube (622) is shown disposedbetween trocar (602) and staple driver (604). Anvil sensing tube (622)includes a mating surface (628) at a distal end (626) that is configuredto engage an annular shelf (640) of an anvil (630). Anvil (630) of thepresent example comprises an anvil head (not shown), a shaft (634), anannular shelf (640) formed on shaft (634), and a coupling feature (notshown). Anvil (630) may be further constructed in accordance with atleast some of the teachings for anvil (40) described herein. When anvil(630) is pushed onto trocar (602), annular shelf (640) engages matingsurface (628) to actuate anvil sensing tube (622) proximally relative totrocar (602) and/or staple driver (604). The coupling feature of anvil(630) selectively couples anvil (630) to trocar (602). By way of exampleonly, the coupling feature may include detents (not shown) formed onshaft (634) that engage with indentations (603) of trocar (602). In thepresent example, if anvil (630) is fully seated on trocar (602) (i.e.,selectively coupled together by the coupling feature), then spring (628)does not eject anvil (630). If anvil (630) is not fully seated on trocar(602) (i.e., the coupling feature did not engage and secure anvil (630)to trocar (602)), then spring (628) ejects anvil (630). While theejection of anvil (630) of the present example occurs when anvil (630)is initially coupled to trocar (602), it should be understood that, inother versions, the ejection of anvil (630) may occur when trocar (602)is actuated proximally via the adjusting knob. In such an alternativeversion, annular shelf (640) engages mating surface (628) when trocar(602) is actuated proximally via the rotating knob. Of course stillfurther configurations for anvil (630) and/or anvil sensing tube (622)will be apparent to one of ordinary skill in the art in view of theteachings herein.

In the present example, notch (624) does not align with arm (616) untiltrocar (602) and anvil (630) are actuated proximally into the “greenzone” described above. In this version, trigger (614) is “locked” untilanvil (630) is both fully seated and positioned in the “green zone.” Inother versions, notch (624) may align with arm (616) of trigger (614)when anvil (630) is initially fully seated on trocar (602). In thisversion, the user may partially pivot trigger (614) to determine thatanvil (630) is fully seated on trocar (602) prior to actuating trocar(602) and anvil (630) proximally via the rotating knob. Accordingly, theuser may be provided with a form of tactile feedback indicating anvil(630) is fully seated on trocar (602). Of course still further versionsof anvil sensing tube (622) and/or annular shelf (640) will be apparentto one of ordinary skill in the art in view of the teachings herein.

For instance, in the example shown in FIG. 13, an alternative anvilsensing tube (722) is shown having a cup (724) configured to receive andguide annular shelf (640) of anvil (630) into engagement with matingsurface (728) of anvil sensing tube (722). Anvil sensing tube (722) maybe further constructed in accordance with anvil sensing tube (622)described above. Accordingly, when annular shaft (640) engages matingsurface (728), anvil sensing tube (722) is configured to permit atrigger, such as trigger (614) to be operated to fire the instrument.While the example shown includes annular shelf (640), in other versions,cup (724) may be configured to mate with a shaft (634) that omitsannular shelf (640).

FIG. 14 depicts an alternative anvil (800) that may be used to engageanvil sensing tubes (622, 722). Anvil (800) comprises an anvil head (notshown), a shaft (802), and a pair of pegs (810) extending outwardly fromshaft (802). Shaft (802) of the present example comprises a split colletconfigured to fit over and selectively couple to a flared portion (822)of a trocar (820). In some versions shaft (802) may comprise a magneticmember (804) to be magnetically guided towards trocar (820). Inaddition, or in the alternative, trocar (820) and/or flared portion(822) may comprise a magnetic member (824) to guide shaft (802) ontotrocar (820). Pegs (810) are configured to engage mating surfaces (628,728) in a substantially similar manner to annular shelf (640).Accordingly, when shaft (802) is coupled to trocar (820) and pegs (810)engage mating surface (628, 728), anvil (800) and trocar (820) can beactuated proximally via an adjusting knob such that anvil sensing tube(622, 722) engages and/or disengages a locking feature, such as arm(616) and notch (624) described above. In some versions, mating surfaces(628, 728) may include a recessed portion (not shown) such that pegs(810) snap into the recessed portion to selectively secure anvil (800)to anvil sensing tubes (622, 722).

In yet a further version, FIG. 15 depicts an alternative trocar (850)having spring-loaded pins (852) biased outwardly against an anvilsensing tube (860). Anvil sensing tube (860) of the present example maybe constructed in accordance with at least some of the teachings foranvil sensing tubes (622, 722) described above. Anvil (870) of thepresent example includes a shaft (872) that has a pair of openings (874)into which pins (860) spring into when shaft (872) is pushed onto trocar(850). Accordingly, when anvil (870) is inserted onto trocar (850),shaft (872) engages anvil sensing tube (860) and pushes anvil sensingtube (860) proximally relative to trocar (850). Once shaft (872) hasactuated anvil sensing tube (860) proximally a predetermined distance,pins (852) spring into openings (874), thereby securing shaft (872) totrocar (850).

Of course still further configurations for anvils (630, 800, 870), anvilsensing tubes (622, 722), and/or trocars (602, 820, 850) will beapparent to one of ordinary skill in the art in view of the teachingsherein.

E. Exemplary Lockout Features

While the foregoing examples have demonstrated various anvil detectionassemblies, it may be preferable for the foregoing assemblies to engageone or more lockout features to release trigger (74) to fire instrument(10). For instance, in some versions it may be preferable for the anvildetection features to pop out a lockout button that must be depressed oroperated by the user to release trigger (74), thereby preventinginstrument (10) from being fired until anvil (40) is properly coupled totrocar (38) and the lockout button is operated by the user.Alternatively, it may be preferable for the anvil detection assembly torelease an indicator and release lockout feature (82) such that theindicator visually indicates that anvil (40) is fully seated on trocar(38) and that the lockout feature can be disengaged to operate trigger(74). Accordingly, it should be understood that the following examplesmay be combined with one or more of the foregoing anvil detectionassemblies and/or with any other anvil detection assembly as will beapparent to one of ordinary skill in the art in view of the teachingsherein.

i. Exemplary Lockout Button Assembly Having a Three Position Button

FIGS. 16A-17 depict an exemplary surgical instrument (900) having anexemplary lockout button assembly (950). Referring initially to FIG.16A, lockout button assembly (950) comprises an anvil sensing shaft(960) extending longitudinally into actuator handle assembly (930) toengage a button (970). Anvil sensing shaft (960) includes a proximal end(962) having an obliquely angled camming surface (964) configured toengage button (970). Anvil sensing shaft (960) may be furtherconstructed in accordance with the teachings for anvil sensing tube(622) described herein, though it should be understood that any of theforegoing anvil detecting assemblies may be used in addition or in thealternative to anvil sensing shaft (960). Actuator handle assembly (930)of the present example includes a body (938) having a first lateral hole(940) (shown in phantom in FIG. 17), a second lateral hole (942), afirst channel (944) (shown in phantom in FIG. 17), a second channel(946), and a vertical slot (948). Button (970) comprises an inner member(972), an intermediate member (974), an intermediate axle (976), and anouter member (978). In the present example, first lateral hole (940) issized to permit intermediate member (974) of button (970) to passtherethrough. Second lateral hole (942) is sized to permit outer member(978) to pass therethrough, but is sized to not permit intermediatemember (974) therethrough. First channel (944) is configured to permitinner member (972) to actuate vertically along first channel (944).Second channel (946) is configured to permit intermediate axle (976) toactuate vertically along second channel (946). Finally, vertical slot(948) is configured to permit intermediate member (974) to actuatevertically therein. Of course still further configurations for button(970) and/or body (938) will be apparent to one of ordinary skill in theart in view of the teachings herein.

Referring to FIGS. 16A and 17, button (970) is initially positioned suchthat inner member (972) mechanically interferes with the actuation oftrigger (932). In the example shown, button (970) is positioned suchthat a protrusion (934) extending from trigger (932) abuts inner member(972) to prevent a user from pivoting trigger (932). As shown in FIG.16A, intermediate member (974) is within first lateral hole (940) andouter member (978) is within second lateral hole (942), thereby forminga substantially flush outer surface of body (938). When anvil sensingshaft (960) is actuated proximally via attachment of an anvil, such asanvil (40), camming surface (964) engages inner member (972) to cambutton (970) outwardly, as shown in FIG. 16B. When button (970) iscammed outwardly, outer member (978) extends outward from second lateralhole (942), intermediate axle (976) substantially aligns with secondchannel (946), intermediate member (974) enters into vertical slot(948), and inner member (972) substantially aligns with first channel(944). As shown in FIG. 16B, outer member (978) provides visualindication (via protruding out of body (938)) that anvil sensing shaft(960) has been actuated proximally relative to actuator handle assembly(930) and that the anvil is fully seated on the trocar. In thisposition, inner member (972) still mechanically interferes with theactuation of trigger (932). In the present example, button (970) isactuated outwardly to the position shown in FIG. 16B by anvil sensingshaft (960) when the anvil is initially coupled to the trocar. Once theanvil is coupled, the user can reduce the anvil gap via an adjustingknob, such as adjusting knob (98) described above. Once the device iswithin the desired operating range, or “green zone,” the user canactuate button (970) downwardly via sliding outer member (978) along theouter surface of body (938). In the present example, intermediate axle(976) slides within second channel (946), intermediate member (974)slides within vertical slot (948), and inner member (972) slides alongfirst channel (944). Accordingly, as shown in FIG. 16C, inner member(972) is actuated to a position such that protrusion (934) of trigger(932) is no longer impeded by inner member (972). The user may then fireinstrument (900). While the foregoing example has been described inreference to a vertical lockout button assembly (950) it should beunderstood that other orientations for assembly (950) may be used, suchas longitudinal and/or any other angle. Furthermore, while the foregoingexample has been described in reference to linear motion to describeactuating the lockout button assembly (950), it should be understoodthat other orientations for actuating the outer member (978) may beused, including rotation.

In some versions, button (970) is cammed via anvil sensing shaft (960)when the anvil and trocar are actuated proximally via the adjustingknob. In addition, or in the alternative, a lockout feature, such aslockout feature (82) described above, may be provided to lockout trigger(932) unless the anvil and trocar are within the “green zone,” therebyproviding a secondary lockout assembly. In yet a further configuration,inner member (972) may be configured such that when button (970) iscammed outwardly via anvil sensing shaft (960), inner member (972) nolonger interferes with protrusion (934) of trigger (932). In thisconfiguration, channels (944, 946), vertical slot (948), intermediatemember (974) and/or intermediate axle (976) may be omitted. Furtherstill, a spring (not shown) may be interposed between intermediatemember (974) and/or inner member (972) and a portion of body (938) tobias button (970) inwardly such that button (970) is not actuatedoutwardly unless anvil sensing shaft (960) cams button (970) against thespring bias. The user may then fire instrument (900). Of course stillfurther configurations for surgical instrument (900) and/or lockoutbutton assembly (950) will be apparent to one of ordinary skill in theart in view of the teachings herein.

By way of example only, FIGS. 18A-18C depict an exemplary surgicalinstrument (1000) having an exemplary lockout button assembly (1050).Referring initially to FIG. 18A, lockout button assembly (1050)comprises an anvil sensing shaft (1060) extending longitudinally intoactuator handle assembly (1030) to engage a button (1070). Anvil sensingshaft (1060) includes a proximal end (1062) having an obliquely angledcamming surface (1064) configured to engage button (1070). Anvil sensingshaft (1060) may be further constructed in accordance with the teachingsfor anvil sensing tube (622) described herein, though it should beunderstood that any of the foregoing anvil detecting assemblies may beused in addition or in the alternative to anvil sensing shaft (1060).Actuator handle assembly (1030) of the present example includes a body(1038) having a hole (1040). Button (1070) comprises an inner member(1072), a paddle feature (1074) on inner member (1072), and an outermember (1076). In the present example, hole (1040) is sized to permitouter member (1076) of button (1070) to pass therethrough. Of coursefurther configurations for button (1070) and/or body (1038) will beapparent to one of ordinary skill in the art in view of the teachingsherein.

Referring to FIG. 18A, button (1070) is initially positioned such thatpaddle feature (1074) mechanically interferes with the actuation of atrigger (1032). In the example shown, a protrusion (1034) extending fromtrigger (1032) abuts paddle feature (1074) to prevent a user frompivoting trigger (1032), though other features may be provided toprevent the user from pivoting trigger (1032). As shown in FIG. 18A,outer member (1076) is within hole (1040) of body (1038), such thatouter member (1076) is substantially flush with the outer surface ofbody (1038). When anvil sensing shaft (1060) is actuated proximally viaattachment of an anvil, such as anvil (40), camming surface (1064)engages inner member (1072) to cam button (1070) outwardly to a secondposition, as shown in FIG. 18B. When button (1070) is cammed outwardly,outer member (1076) extends outward from hole (1040). Outer member(1076) thus provides a visual indication (by protruding out of body(1038)) that anvil sensing shaft (1060) has been actuated proximallyrelative to actuator handle assembly (1030) and that the anvil is fullyseated on the trocar. Once the anvil is coupled, the user can reduce theanvil gap via an adjusting knob, such as adjusting knob (98) describedabove. Paddle feature (1074) continues to prevent actuation of trigger(1032) at this stage. Once the anvil gap is within the desired operatingrange, or “green zone,” the user rotates button (1070) via outer member(1076) to a third position. As shown in FIG. 18C, in one merelyexemplary version, the user rotates button (1070) such that paddlefeature (1074) is oriented approximately 180 degrees relative to theinitial position shown in FIG. 18A. Accordingly, paddle feature (1074)is rotated to a position such that protrusion (1034) of trigger (1032)is no longer impeded by paddle feature (1074). The user may then fireinstrument (900).

FIGS. 19A-19F depict yet another exemplary surgical instrument (1100)having an exemplary lockout button assembly (1150). Referring initiallyto FIG. 19A, lockout button assembly (1150) comprises an anvil sensingpin (1160) coupled to an anvil sensing rod (not shown) that extendslongitudinally into an actuator handle assembly to engage a button(1170). In the present example, button (1170) comprises an inner portion(1172), an intermediate portion (1176) and an outer portion (1178). Aspring (1180) is associated with inner portion (1172) and biases button(1170) laterally relative to a body (1138) (a cut away portion of whichis shown in FIGS. 19A and 19C, but is omitted in FIGS. 19B and 19D-F forclarity). In the present example, outer portion (1178) of button (1170)is initially positioned within an opening (1139) in body (1138) and issubstantially flush with the exterior of body (1138) in the firstposition. Inner portion (1172) of button (1170) includes a hole (1174)that is configured to receive anvil sensing pin (1160). Of course itshould be understood that hole (1174) may be formed in intermediateportion (1176) and/or outer portion (1178) or, in some versions, omittedentirely. Intermediate portion (1176) of the present example comprises arectangular member defined by a first dimension d1 and a seconddimension d2 such that d2 is less than d1. Intermediate portion (1176)will be described in more detail below. Inner portion (1172) and outerportion (1178) are depicted as cylindrical members having diameters thatare substantially equal to first dimension d1, though this is merelyoptional and inner portion (1172) and/or outer portion (1178) may haveother shapes and/or configurations as will be apparent to one ofordinary skill in the art in view of the teachings herein.

Surgical instrument (1100) also includes a firing rod (1140) having astepped aperture (1142) formed therethrough and configured to receivebutton (1170). Firing rod (1140) is coupled to a trigger (not shown) andis operable to actuate a staple driver (not shown) of instrument (1100).In the present example, stepped aperture (1142) comprises a firstportion (1144) and a second portion (1146) with a step (1148). Firstportion (1144) is sized to be substantially equal to first dimension d1such that intermediate portion (1176) of button (1170) can actuatelaterally through first portion (1144). Second portion (1146) is locatedproximally of first portion (1144) and is reduced in size by step(1148). Second portion (1146) is sized to be substantially equal tosecond dimension d2 of intermediate portion (1176) such that firing rod(1140) can actuate longitudinally relative to intermediate portion(1176) when button (1170) is rotated to a third position, shown in FIGS.19D-19F and described in greater detail below.

As shown in FIG. 19A, initially anvil sensing pin (1160) is insertedthrough hole (1174) of inner portion (1172). In some versions, anvilsensing pin (1160) may be only partially inserted into hole (1174)and/or hole (1174) does not extend through inner portion (1172) ofbutton (1170). In this first position, anvil sensing pin (1160) preventsspring (1180) from biasing button (1170) laterally to protrude outerportion (1178) out of body (1138) through opening (1139). In addition,intermediate portion (1176) is initially positioned such thatintermediate member (1176) is positioned within first portion (1144) ofstepped aperture (1142) and is oriented with first dimension d1perpendicular to the vertical plane along which the central axis offiring rod (1140) extends. As shown in FIG. 19A, intermediate portion(1176) interferes with distal actuation of firing rod (1140) due to step(1148) abutting intermediate portion (1176).

Once an anvil, such as anvil (40) described above, is fully seated,anvil sensing pin (1160) is retracted distally relative to button (1170)to disengage from hole (1174), as shown in FIG. 19B. Spring (1180) urgesbutton (1170) laterally relative to body (1138) (shown in FIG. 19A),such that outer portion (1178) protrudes through opening (1139) to asecond position shown in FIG. 19C. In addition, with button (1170) inthe second position, inner portion (1172) is positioned within firstportion (1144) of stepped aperture (1142) such that firing rod (1140)cannot be actuated longitudinally relative to button (1170). In someversions, spring (1180) may be omitted and button (1170) may be manuallyactuated to the second position.

With outer portion (1178) protruding from body (1138) and thereby beingexposed for grasping, the user rotates button (1170) to a thirdposition, for instance by rotating button (1170) 90 degrees, such thatintermediate portion (1176) is oriented with second dimension d2perpendicular to the vertical plane along which the central axis offiring rod (1140) extends, as shown in FIG. 19D. In this position, innerportion (1172) is still positioned within first portion (1144) ofstepped aperture (1142) such that firing rod (1140) cannot be actuatedlongitudinally relative to button (1170). The user then actuates button(1170) into body (1138) such that intermediate portion (1176) is alignedwithin stepped aperture (1142), as shown in FIG. 19E. As shown, withintermediate portion (1176) rotated to have second dimension d2perpendicular to the vertical plane along which the central axis offiring rod (1140) extends, firing rod (1140) may then be actuatedlongitudinally relative to button (1170) since step (1148) andintermediate portion (1176) no longer abut and engage each other.Accordingly, the user may then fire instrument (1100). Of course otherconfigurations and or assemblies will be apparent to one of ordinaryskill in the art in view of the teachings herein.

ii. Exemplary Lockout Button Assembly Having a Palm Button

FIG. 20A-20C depicts an exemplary alternative surgical instrument (1200)having exemplary lockout button assembly (1250). Referring initially toFIG. 20A, surgical instrument (1200) of the present example comprises astapling head assembly (not shown), a shaft assembly (1220), and anactuator handle assembly (1230). Shaft assembly (1220) extends distallyfrom actuator handle assembly (1230) and the stapling head assembly iscoupled to a distal end of shaft assembly (1220). In brief, actuatorhandle assembly (1230) includes a trigger (1232) that is operable toactuate a staple driver (not shown) of the stapling head assembly todrive a plurality of staples (not shown) out of the stapling headassembly. The staples are bent to form completed staples by an anvil(not shown), such as anvil (40), that is attached to a trocar thatextends out from the distal end of instrument (1200). Accordingly,tissue may be stapled utilizing instrument (1200). The stapling headassembly, shaft assembly (1220), and actuator handle assembly (1230) maybe further constructed in accordance with stapling head assembly (20),shaft assembly (60), and actuator handle assembly (70) described above.

In the example shown, lockout button assembly (1250) of the presentexample comprises an anvil sensing shaft (1260), a palm button (1270),and a pivot member (1280). FIG. 20A depicts anvil sensing shaft (1260),palm button (1270), and pivot member (1280) in an initial, lockedposition. In this position, pivot member (1280) is configured tomechanically interfere with pivoting of a lockout feature (1234) suchthat trigger (1232) cannot be actuated. By way of example only, pivotmember (1280) mechanically interferes with lockout feature (1234) via anarm (1286) that extends outwardly from a distal end (1284) of pivotmember (1280). Lockout feature (1234) may be constructed in substantialaccordance with lockout feature (82) described herein. Palm button(1270) in the present example is substantially flush with the exteriorof instrument (1200), though this is merely optional and palm button(1270) may be inset or protrude relative to the exterior of instrument(1200). Anvil sensing shaft (1260) includes a proximal end feature(1262) configured to engage palm button (1270) and pivot member (1280).In the initial position shown in FIG. 20A, proximal end feature (1262)is disengaged from palm button (1270) and pivot member (1280). By way ofexample only, proximal end feature (1262) may be located distally ofboth palm button (1270) and pivot member (1280) such that a space isformed between palm button (1270) and pivot member (1280). Accordingly,even if a user attempts to actuate of palm button (1280) inwardly towardpivot member (1280) in this initial, locked position, palm button (1270)does not engage pivot member (1280). Thus, pivot member (1280) and arm(1286) remain in a position to mechanically interfere with lockoutfeature (1234). In some versions, pivot member (1280) may include aspring (not shown) to bias arm (1282) towards interfering with lockoutfeature (1234).

In the present example, proximal end feature (1262) includes a cammingsurface (1264), a button surface (1266), and a lever arm (1268). Asshown in FIG. 20B, camming surface (1264) is operable to engage and campalm button (1270) outwardly when anvil sensing shaft (1260) is actuatedproximally relative to actuator handle assembly (1230), such as byattachment of an anvil and adjustment of the anvil and trocar into the“green zone.” Palm button (1270) may thus provide a visual indicatorthat the anvil is properly attached and the device is within theoperating range. Once palm button (1270) is cammed outwardly, at leastpart of palm button (1270) is adjacent to button surface (1266) suchthat palm button (1270) may engage button surface (1266) when palmbutton (1270) is pushed inwardly. In addition, lever arm (1268) ofproximal end feature (1262) is aligned with a proximal end (1282) ofpivot member (1280). Anvil sensing shaft (1260) may be furtherconstructed in accordance with the teachings for anvil sensing tube(622) described herein, though it should be understood that any of theforegoing anvil detecting assemblies may be used in addition or in thealternative to anvil sensing shaft (1260).

When palm button (1270) and proximal end feature (1262) are aligned, asshown in FIG. 20B, the user presses palm button (1270) inwardly, therebyengaging lever arm (1268) with proximal end (1282) of pivot member(1280). Accordingly, when lever arm (1268) pivots pivot member (1280)about pivot (1281) by a predetermined amount, shown in FIG. 20C, arm(1286) no longer mechanically interferes with lockout feature (1234).The user may then pivot lockout feature (1234) to unlock trigger (1232)to fire instrument (1200). While one merely exemplary configuration fora lockout assembly (1250) having a palm button (1270) has beendescribed, still further configurations will be apparent to one ofordinary skill in the art in view of the teachings herein. For instance,in some versions proximal end feature (1262) omits camming surface(1264) and palm button (1270) does not cam outwardly relative to theexterior of instrument (1200).

iii. Exemplary Lockout Button Assembly Having an Interlock Assembly

FIGS. 21A-23 depict yet another exemplary lockout button assembly (1300)comprising a spring-loaded push rod (1310), a spring-loaded pin (1320),and a pivotable lockout feature (1340). FIG. 21A, depicts spring-loadedpush rod (1310), spring-loaded pin (1320), and pivotable lockout feature(1340) shown in an initial or locked position and contained within abody (1350) of an exemplary surgical instrument, such as instrument (10)described above. In the present example, body (1350) includes a pin hole(1352) sized to permit an outer portion (1338) of pin (1320) to extendtherethrough. In some versions, pin hole (1352) may be sized to permitouter portion (1338) to extend therethrough, but comprises a smallerdiameter than an intermediate portion (1332), thereby only permittingouter portion (1338) to protrude through. Of course it should beunderstood that pin hole (1352) is merely optional and may be omitted insome versions. Body (1350) may be further constructed in accordance withat least some of the teachings for body (72) described above.

Referring first to spring-loaded push rod (1310), push rod (1310)comprises an elongated rod extending longitudinally within a surgicalinstrument. A spring (1312) engages a proximal end of push rod (1310) toprovide a distal bias. By way of example only, push rod (1310) may beconfigured to be actuated proximally when an anvil, such as anvil (40)is coupled to a trocar, such as trocar (38), and both the anvil andtrocar are actuated into the operating range or “green zone” describedabove. Referring to FIG. 22 briefly, push rod (1310) includes a lateralhole (1314) and a longitudinal slot (1316) formed through push rod(1310). In the present example, lateral hole (1314) is sized to permitan intermediate portion (1332) of pin (1320) to pass through lateralhole (1314). Longitudinal slot (1316) is sized to permit an intermediateaxle (1334) of pin (1320) to slide along longitudinal slot (1316). Asshown in FIG. 22, pin (1320) and push rod (1310) are shown in theinitial or locked position with push rod (1310) actuated distally viaspring (1312), thereby laterally restraining pin (1320) with axle (1334)within slot (1316). In addition, or in the alternative, push rod (1310)may be constructed in accordance with the teachings for anvil sensingtube (622) described herein, though it should be understood that any ofthe foregoing anvil detecting assemblies may be incorporated into thepresent lockout button assembly (1300). Still other configurations forpush rod (1310) will be apparent to one of ordinary skill in the art inview of the teachings herein.

FIG. 21A also depicts pin (1320) coupled to a spring (1322) such thatpin (1320) is biased laterally toward pin hole (1352). Pin (1320)comprises an inner portion (1324), an inner axle (1328), an intermediateportion (1332), an intermediate axle (1334), and an outer portion(1338). In the present example, intermediate portion (1332) and outerportion (1338) are substantially dimensioned the same while innerportion (1324) includes an enlarged portion (1326). Of course it shouldbe understood that this is merely optional. In some versions, innerportion (1324), intermediate portion (1332), and outer portion (1338)are all substantially dimensioned the same. In other versions, innerportion (1324), intermediate portion (1332), and outer portion (1338)all comprise different sizes and/or shapes. Accordingly, the lateralactuation of pin (1320) may be controlled by having varying sizes and/orshapes for inner portion (1324), intermediate portion (1332), and outerportion (1338). Inner axle (1328) couples inner portion (1324) tointermediate portion (1332) and is substantially smaller than eitherinner portion (1324) and/or intermediate portion (1332). In the presentexample, axle (1328) is configured to permit lockout feature (1340) tobe pivoted while axle (1328) rides within an arcuate slot (1349),described in greater detail below. Intermediate axle (1334) couplesintermediate portion (1332) to outer portion (1338) and is substantiallysmaller than either intermediate portion (1332) and/or outer portion(1338). In the present example, axle (1334) is configured to permit pushrod (1310) to be actuated proximally relative to axle (1334) while axle(1334) rides within longitudinal slot (1316), described above.

Lockout feature (1340) of the present example comprises an arm (1342), apivot member (1344), and a main body (1346). Arm (1342) is configured toabut a trigger (not shown) in a substantially similar manner to lockoutfeature (82) described above. Pivot member (1344) is configured tocouple to a portion of body (1350), such as a recess, to permit lockoutfeature (1340) to be pivoted relative to body (1350). Main body (1346)comprises a sector, or pie-shaped, component having a hole (1348) and anarcuate slot (1349). Hole (1348) is sized to permit passage ofintermediate portion (1332) of pin (1320) through hole (1348), but doesnot permit enlarged portion (1326) of inner portion (1324) to passthrough. Arcuate slot (1349) is configured to permit inner axle (1328)to be slidably received within arcuate slot (1349). Accordingly, wheninner axle (1328) is within hole (1348), such as that shown in FIG. 21B,lockout feature (1340) may be pivoted such that arcuate slot (1349)slides about inner axle (1328). Accordingly, when lockout feature (1340)is pivoted, arm (1342) no longer impedes actuation of the trigger,thereby allowing the user to fire the instrument. When lockout feature(1340) is in the first or locked position shown in FIGS. 21A and 23,lockout feature (1340) prevents the trigger from actuating and lockoutfeature (1340) is prevented from pivoting via the interference providedby the presence of intermediate portion (1332) of pin (1320) within hole(1348). Of course still further configurations for lockout feature(1340) will be apparent to one of ordinary skill in the art in view ofthe teachings herein.

Referring now to the sequence depicted in FIGS. 21A-21B, initiallyspring-loaded push rod (1310), spring-loaded pin (1320), and pivotablelockout feature (1340) are in an initial or locked position. In thisposition, arm (1346) of lockout feature (1340) inhibits actuation of thetrigger, lockout feature (1340) is prevented from pivoting because ofthe presence of intermediate portion (1332) within hole (1348), and pin(1320) is prevented from laterally actuating via spring (1322) becauseintermediate portion (1332) abuts push rod (1310) and is not alignedwith lateral hole (1314). In the example shown, outer portion (1338) iswithin pin hole (1352) and is flush with the exterior of body (1350).When the user attaches an anvil, such as anvil (40), to a trocar, suchas trocar (38), anvil may engage a distal end of push rod (1310) andbegin to actuate push rod (1310) proximally against the bias provided byspring (1312). As noted with some of the foregoing examples, spring(1312) may provide a sufficient distal force such that the anvil isejected off of the trocar if the anvil is not fully seated. As the anvilis coupled to the trocar, longitudinal slot (1316) begins to slideproximally relative to intermediate axle (1334) to move lateral hole(1314) into closer alignment with intermediate portion (1332). Once theanvil and trocar are positioned within the operating range or “greenzone,” lateral hole (1314) and intermediate portion (1332) align. Spring(1322) urges pin laterally, thereby pushing intermediate portion (1332)into lateral hole (1314) and aligns inner axle (1328) with arcuate slot(1349) of lockout feature (1340), as shown in FIG. 21B. Enlarged portion(1326) abuts lockout feature (1340) to prevent spring (1322) fromejecting pin (1320) too far or out of the device. With inner axle (1328)and arcuate slot (1349) aligned, the user may pivot lockout feature(1340) about pivot member (1344), thereby releasing the trigger andpermitting the user to fire the instrument. In some versions, arotational spring (not shown) may be coupled to lockout feature (1340)to automatically pivot lockout feature (1340), though this is merelyoptional. In the present example, spring (1322) also extends outerportion (1338) of pin (1320) out of pin hole (1352). The protrusion ofouter portion (1338) through pin hole (1352) can be used as a visualindicator by the user that the instrument is within the operating rangesuch that lockout feature (1340) may be pivoted to release the trigger.Of course, in some versions outer portion (1338) and/or pin hole (1352)may be omitted. Still further configurations for lockout button assembly(1300) will be apparent to one of ordinary skill in the art in view ofthe teachings herein.

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Embodiments of the present invention have application in conventionalendoscopic and open surgical instrumentation as well as application inrobotic-assisted surgery. For instance, those of ordinary skill in theart will recognize that various teaching herein may be readily combinedwith various teachings of U.S. Pat. No. 6,783,524, entitled “RoboticSurgical Tool with Ultrasound Cauterizing and Cutting Instrument,”published Aug. 31, 2004, the disclosure of which is incorporated byreference herein.

By way of example only, embodiments described herein may be processedbefore surgery. First, a new or used instrument may be obtained and ifnecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device may also be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, or steam.

Embodiments of the devices disclosed herein can be reconditioned forreuse after at least one use. Reconditioning may include any combinationof the steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, embodiments of the devices disclosed herein may bedisassembled, and any number of the particular pieces or parts of thedevices may be selectively replaced or removed in any combination. Uponcleaning and/or replacement of particular parts, embodiments of thedevices may be reassembled for subsequent use either at a reconditioningfacility, or by a surgical team immediately prior to a surgicalprocedure. Those skilled in the art will appreciate that reconditioningof a device may utilize a variety of techniques for disassembly,cleaning/replacement, and reassembly. Use of such techniques, and theresulting reconditioned device, are all within the scope of the presentapplication.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

I/We claim:
 1. An apparatus for stapling tissue the apparatuscomprising: (a) an actuator handle assembly having a trigger pivotablymounted to a body; and (b) a stapling head assembly comprising: i. astaple driver, ii. a pointed rod, and iii. an anvil detection feature;wherein the trigger is operable to actuate the staple driver distallyrelative to the actuator handle assembly; and wherein the anvildetection feature is operable to prevent the trigger from pivoting inthe absence of a seated anvil.
 2. The apparatus of claim 1 whereinactuator handle assembly further comprises a lockout feature, whereinthe lockout feature is moveable from a first position to a secondposition, wherein the lockout feature in the first position engages thetrigger to prevent pivoting of the trigger, wherein the lockout featurein the second position permits pivoting of the trigger, wherein theanvil detection feature is operable to prevent the lockout feature frompivoting from the first position to the second position.
 3. Theapparatus of claim 2 wherein the anvil detection feature comprises atranslatable member having a protrusion.
 4. The apparatus of claim 3wherein the translatable member is biased distally relative to theactuator handle assembly.
 5. The apparatus of claim 4 wherein attachmentof an anvil to the pointed rod actuates the translatable rod proximally.6. The apparatus of claim 1 wherein the anvil detection featurecomprises an anvil sensing tube.
 7. The apparatus of claim 6 wherein theanvil sensing tube is coaxially disposed about the pointed rod.
 8. Theapparatus of claim 6 wherein the trigger comprises a trigger arm,wherein the trigger arm abuts the anvil sensing tube when the anvilsensing tube is in a first position.
 9. The apparatus of claim 8 whereinthe anvil sensing tube comprises a recess, wherein the recess is sizedto permit trigger arm to pivot therethrough when the anvil sensing tubeis in a second position.
 10. The apparatus of claim 6 wherein the anvilsensing tube comprises a distal cup configured to receive a shaft of ananvil.
 11. The apparatus of claim 1 wherein the anvil detection featurecomprises a resiliently biased tab on an exterior surface of the pointedrod.
 12. The apparatus of claim 11 wherein the tab is operable to engagea distal end of the staple driver.
 13. The apparatus of claim 11 whereinthe tab is operable to prevent the pointed rod from actuating proximallyrelative to the actuator handle assembly.
 14. The apparatus of claim 11further comprising an anvil selectively coupleable to the pointed rod,wherein the anvil is operable to compress the tab against the pointedrod.
 15. The apparatus of claim 1 wherein the anvil detection featurecomprises a pair of spring clips, wherein the spring clips are disposedwithin a slot formed in the pointed rod, and wherein at least a portionof the spring clips extend laterally out of the pointed rod in theabsence of a seated anvil.
 16. An surgical instrument trigger lockoutassembly comprising: (a) a push rod; (b) a pivotable lockout feature;and (c) a button inserted through the push rod and the lockout feature,wherein the button comprises: i. a first portion, ii. a second portion,and iii. a third portion; wherein the second portion of the button isoperable to prevent the lockout feature from pivoting when button is ina first lateral position; and wherein the push rod is operable toactuate longitudinally in response to the coupling of an anvil.
 17. Thelockout assembly of claim 16 wherein the push rod comprises a distalhole and a longitudinal slot, wherein the hole is sized to permit thesecond portion of the button to laterally slide therethrough, whereinthe slot is sized to permit the push rod to actuate longitudinally whenthe first portion of the button is extended therethrough.
 18. Thelockout assembly of claim 17 further comprising a spring coupled to thethird portion of the button, wherein the spring biases the buttonlaterally, wherein the second portion abuts a side of the push rod whenthe button is in a first position.
 19. The lockout assembly of claim 16wherein the lockout feature comprises a proximal hole and an arcuateslot, wherein the hole is sized to permit the second portion of thebutton to laterally slide therethrough, wherein the slot is sized topermit the lockout feature to pivot when the third portion of the buttonis extended therethrough.
 20. An apparatus for stapling tissue theapparatus comprising: (a) an actuator handle assembly comprising: i. abody, ii. a trigger pivotably mounted to the body, and iii. a buttoncoupled to the body; and (b) a stapling head assembly comprising: i. astaple driver, ii. a pointed rod, and iii. an anvil sensing shaft;wherein the trigger is operable to actuate the staple driver distallyrelative to the actuator handle assembly; and wherein the anvil sensingshaft is operable to cam the button outwardly from the body when theanvil sensing shaft is actuated proximally.